Safe Ground Coupling System
The "Safe Coupling System" is an award-winning*** ground coupling system, designed and manufactured by Don-Bur, which eliminates the need for a driver to access the area between the cab and trailer during the coupling process.
The coupling procedure for articulated units has stubbornly remained a source of potential injury to drivers. Service line connector design has altered significantly over the years, but the driver has always had to climb up onto the catwalk; working at height, in a difficult cramped and often dirty environment.
All this can lead to falls, slips, trips, strains and grazing on protrusions on the cab rear. The only way to eliminate these risks is to eliminate the need to access the catwalk area entirely.
The Don-Bur Safe Coupling System is a unique pneumatically-powered ground coupling system that does just that. During transit, the coupling plate is located centrally on the front bulkhead, but this plate rotates outwards and downwards to a chest height position when the driver is standing on the ground next to the tractor.
***Winner Motor Transport Awards 2011 (Innovation Category)
Judges looked for evidence of how creative thinking was applied to solve a problem. Entrants had to show what the problem or issue was, how the innovation solution was arrived at and how it delivered significant benefits.
"This is a fabulous recognition for a pro-active innovation in the industry. This was a project that was realised by Don-Bur for the whole industry and not just DHL". (Russell Clark, SHE Director, DHL Supply Chain)
Judges Comments: "A great practical innovation with clear safety benefits. Anything that improves safety is a winning innovation".
*** Winner SHP IOSH awards 2010 (Innovation Category)
Quote SHP IOSH Winners Brochure
"A major collaboration between logistics business DHL and trailer manufacturer Don-Bur, along with a number of leading vehicle manufacturers, resulted in the "Safe Coupling System" device, which enables all drivers to comfortably couple trailers at ground level. Addressing the long-standing source of potential injury during the coupling procedure, i.e. the necessity to climb up on to the vehicle's catwalk and work at height, often in a cramped environment, the Safe Coupling System uses a fully automatic, air-powered arm that rotates from its vertical transit position to a position where the coupling plate is at a comfortable user height, by the side of the trailer. The female airline connectors are placed vertically, allowing the driver to apply force without bending or twisting. After coupling, a button located on the side of the trailer automatically powers the arm back to its transit location. The Safe Coupling System is attached to the EBS system and prevents the brakes from releasing until the arm is correctly stowed. The coupling desiggn mirrors the position and configuration of the tractor coupling and reduces the incidence of line entanglement. An excellent solution to a very real problem, said our judges, which is ilikely to be used widely, and has the potential to make a big difference."
Coupling Process (Uncoupling is a mirror process)
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Parked Position |  |
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Driver reverses in the normal fashion |  |
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Driver pulls Safe Coupling System down... |  |
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...to chest height. |  |
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The driver can then connect as normal. |  |
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The driver pushes a button on the side rave which... |  |
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...retracts the coupling plate to normal transit position. |  |
Key Features & Benefits:
- Eliminates need to access the catwalk
- Extends beyond width of trailer for easy access.
- Rotates downwards for optimised coupling height.
- Ergonomic, easy-to-use design.
- Tested, durable construction.
- Driver stays clean
Safety Systems:
- Trailer brakes automatically apply when Safe Coupling System is in coupling position which prevents drive-away.
- Safe Coupling System plate auto-retracts to transit position if trailer starts to move.
- Coupling process cannot be “bypassed”, enforcing a safe system of work.
News & Reports
July 23rd 2009: It's as easy as 1,2,3, says Biglorryblog! (+ Video Footage)
http://www.roadtransport.com/blogs/big-lorry-blog/2009/07/donburdhl-safe-suzie-coupling.html
October 13th 2009: How to stop drivers becoming “fall-guys” (+ Video Footage)
http://www.roadtransport.com/blogs/big-lorry-blog/2009/10/bigloryblog-and-the-don-burdhl.html
JLT (Jardine Lloyd Thompson) Independant Risk Assessment
